Prediction of cutting force in ball-end milling of sculptured surface using improved Z-map

Wei, Zhaocheng; Wang, M. J.; Cai, Yiqiao; Wang, S. F.

doi:10.1007/s00170-013-4909-x

Cited by 42 publications

(18 citation statements)

References 20 publications

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“…As briefly noted in the previous section, MMS is a semianalytical perturbation method used to examine the local nonlinear dynamic characteristics of DDEs [9]. Although it is a useful and effective method that can provide physical insights into the complicated dynamic nature of the present nonlinear ball-end milling system (as explained in Section 4), MMS is intrinsically limited in that the nonlinearity must be small enough to obtain rapid convergence of the associated asymptotic solutions [28].…”

Section: Periodic Solutions Of the Nonlinear Ball-end Milling System mentioning

confidence: 99%

“…Furthermore, to determine the stability of ball-end milling systems, investigation of the cutting force effect is also required. Based on the relation between the cutting force and the uncut chip thickness in the ball-end milling process, two types of models are commonly used to predict the cutting forces: nonlinear models [1][2][3][4] and linear models [5][6][7][8][9]. Nonlinearity in the cutting force model is known to exist because of the size effect [10].…”

Section: Introductionmentioning

confidence: 99%

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Nonlinear Modeling and Dynamic Simulation Using Bifurcation and Stability Analyses of Regenerative Chatter of Ball-End Milling Process

Jung¹,

Ngo²,

Son³

et al. 2016

Mathematical Problems in Engineering

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A dynamic model for a ball-end milling process that includes the consideration of cutting force nonlinearities and regenerative chatter effects is presented. The nonlinear cutting force is approximated using a Fourier series and then expanded into a Taylor series up to the third order. A series of nonlinear analyses was performed to investigate the nonlinear dynamic behavior of a ball-end milling system, and the differences between the nonlinear analysis approach and its linear counterpart were examined. A bifurcation analysis of points near the critical equilibrium points was performed using the method of multiple scales (MMS) and the method of harmonic balance (MHB) to analyse the local chatter behaviors of the system. The bifurcation analysis was conducted at two subcritical Hopf bifurcation points. It was also found that a ball-end milling system with nonlinear cutting forces near its critical equilibrium points is conditionally stable. The analysis and simulation results were compared with experimental data reported in the literature, and the physical significance of the results is discussed.

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Section: Periodic Solutions Of the Nonlinear Ball-end Milling System mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Nonlinear Modeling and Dynamic Simulation Using Bifurcation and Stability Analyses of Regenerative Chatter of Ball-End Milling Process

Jung¹,

Ngo²,

Son³

et al. 2016

Mathematical Problems in Engineering

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“…Currently, the path generation methods of processing freedom hook face are mainly include parallel section method, 2 isoperimetric line method, 3 equal chord error method, 4,5 equal residual height method, isometric bias method, polyhedral method, feature Extraction method, and Z-map method. [6][7][8] After the path generation method is determined, the row spacing and path points of the ultrasonic surface strengthening on each path and their corresponding tool poses of ultrasonic surface strengthening need to be determined according to the process requirements. The choice of row spacing determines the final quantity of paths.…”

Section: Introductionmentioning

confidence: 99%

Research on path planning of robotic ultrasonic surface strengthening for turbine blade based on dynamic response of ultrasonic surface strengthening

Fang

Zhang

Chen

et al. 2019

Advances in Mechanical Engineering

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In order to realize the automatic strengthening for turbine blades, a path planning method for robotic ultrasonic surface strengthening is proposed. A constitutive model of nonlinear isotropic strengthening–kinematic hardening is analyzed to establish the dynamic response model of ultrasonic surface strengthening on the turbine blade. According to the dynamic response model, the impact depth of the ultrasonic working head was obtained. Then, a path planning method of robotic ultrasonic surface strengthening for turbine blades is proposed on the basis of impact depth of working head, and it can improve both the uniformity of path distribution and contour accuracy. It not only ensures the processing accuracy but also meets the uniformity requirement of coverage. This path planning method provides a new surface strengthening technology for turbine blades.

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“…As the cutting force is directly related to the uncut chip thickness, the uncut chip thickness in ball-end high-speed milling of 3D curved surface can be calculated or simulated and with the known cutting force coefficients, the cutting force can be simulated. Wei et al [20] presented a prediction model for cutting force in three-axis ball-end milling to deal with the problems of varying feed direction, varying cutter engagement, and the consequent varying cutting forces in sculptured surface machining. However, the influence of cutting speed was not considered in the model.…”

Section: Introductionmentioning

confidence: 99%

A new cutting force modeling method in high-speed milling of curved surface with difficult-to-machine material

Zhang

Wang

et al. 2015

Int J Adv Manuf Technol

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The high-speed milling technology for difficultto-machine material has come to be a hotspot in the industry field. Regarding the high-speed milling of Inconel 718 parts with curved surface, the variation of the geometric features of the curved surface will lead to the sharp fluctuation of the cutting force as well as the vibration of machine tool. In this way, it not only makes a severe impact on the surface machining quality and the tool life but also greatly affects the efficiency of the high-speed milling. For the milling force is an important physical concept to comprehensively reflect the milling process and the cutting speed is one of the main factors that affect the cutting force when the cutting volume is small in the high-speed milling of Inconel 718 parts with curved surface, a new cutting force modeling method is proposed based on the geometric characteristics of the curved surface and the spindle speed, which can be used to predict the cutting force fluctuation under different cutting speed. The experimental results show that the proposed cutting force model can effectively forecast the amplitude and the change trend of the cutting force. The achievements of this study will provide the theoretical basis for the optimization of machining parameters in high-speed milling of curved surface with difficult-to-machine material and enrich the processing and manufacturing theory for parts with curved surface.

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Prediction of cutting force in ball-end milling of sculptured surface using improved Z-map

Cited by 42 publications

References 20 publications

Nonlinear Modeling and Dynamic Simulation Using Bifurcation and Stability Analyses of Regenerative Chatter of Ball-End Milling Process

Nonlinear Modeling and Dynamic Simulation Using Bifurcation and Stability Analyses of Regenerative Chatter of Ball-End Milling Process

Research on path planning of robotic ultrasonic surface strengthening for turbine blade based on dynamic response of ultrasonic surface strengthening

A new cutting force modeling method in high-speed milling of curved surface with difficult-to-machine material

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